Every manufacturer would like to improve overall efficiency. Doing so allows them to compete globally while increasing their bottom lines. Many techniques can be used to improve efficiency, and it is a matter of finding the right one for each organization.
What is Efficiency?
Efficiency must be defined before it can be improved. Many define efficiency as the ratio of products a facility produces relative to the resources it uses during production. Efficiency is the ratio of output to input. However, a company might have a different definition they want to use before trying to improve it using the following techniques or others.
Lean Manufacturing
Lean manufacturing strives to reduce waste while increasing customer value. Continuous process improvement is a building block of this manufacturing philosophy. Toyota was the first to employ lean manufacturing to eliminate waste, and the company was so successful this manufacturing process soon expanded worldwide. Turn to lean consulting services to learn more about this process and how it may benefit the company.
Efficiency Metrics
Companies must have metrics to determine where improvements are needed and whether progress is being made. However, the metrics used differ by organization. One manufacturer might benefit from measuring overall equipment efficiency (OEE), while another needs information on overall operations effectiveness (OOE). Determine which aspects of the manufacturing process need to be measured and choose the metrics accordingly.
Streamlined Communications
Communication in manufacturing is essential. Streamlining these communications will improve efficiency, allowing potential problems to be solved before they escalate.
Quality and Consistency With the Help of Robotics
Robotic automation improves quality and consistency, leading to improved efficiency. Machine downtime is minimized, and automated systems can take on many tasks. They may handle sorting, packaging, palletizing, and more. Conveyor systems move parts and products quickly and efficiently when the correct flow rate is established and the loads are optimized.
Minimize Downtime
Downtime comes in many forms. Machines may sit idle while employees are on break. The facility may be understaffed, leaving workers unavailable to run the machines, or they may need maintenance that must occur during regular working hours. Find ways to minimize downtime and watch overall efficiency improve. Maintenance may be rescheduled outside regular business hours. Employees might be cross-trained to work one machine while another is being maintained, and employee breaks may be staggered so no machine sits idle.
Plant Layout Optimization
A facility’s layout directly impacts manufacturing efficiency. Workers must travel farther to carry out routine tasks when the plant layout is inefficient. Downtime increases and employees are stressed. By rearranging the plant, a company can avoid these issues. It won’t need to spend a lot of money to do so. The focus needs to be on finding ways to minimize movement waste. Break tasks into individual steps and find ways to allow workers to move from one step to the next using the shortest path possible. They will get more done with shorter travel distances and improve their morale.
Technology Training
Employees become frustrated when asked to use the latest techniques and technologies but receive no training. A company can improve efficiency and have happier employees by providing this training. Happy employees are more productive, so the company benefits from this investment.
Improving manufacturing efficiency isn’t difficult when one knows what to do. Choose one technique or tip to implement and follow through. After an established period, try a second tip or technique. With time, improvements will be seen, and manufacturers will know which methods to use and which to discard. With this information, they will see an overall efficiency increase.
